Mass transfer packing element and method of making the same

Abstract

A ceramic mass transfer packing element that includes a planar end surface which intersects an internal wall's geometric plane at an acute angle is disclosed. A process for making the packing element and an apparatus that uses the packing element are also disclosed.

What is claimed is: 
     
       1. A mass transfer packing element, comprising:
 (a) a continuous peripheral wall comprising a first end and a second end, wherein said peripheral wall surrounds a passageway through said element, said first end defines a first planar surface and said second end defines a second planar surface 
 (b) disposed within said passageway a first internal wall defines a first geometric plane and a second internal wall defines a second geometric plane; wherein said first and second geometric planes are mutually parallel and intersect said first and second planar surfaces at an acute angle; and 
 (c) said peripheral wall and said internal walls comprise ceramic material. 
 
     
     
       2. The packing element of  claim 1  wherein said first geometric plane intersects said first planar surface at an angle less than 80°. 
     
     
       3. The packing element of  claim 1  wherein said first geometric plane intersects said first planar surface at an angle less than 70°. 
     
     
       4. The packing element of  claim 1  wherein said first geometric plane intersects said first planar surface at an angle less than 60° and greater than 30°. 
     
     
       5. The packing element of  claim 1  wherein said first and second planar surfaces are mutually parallel. 
     
     
       6. The packing element of  claim 1  wherein said element has a maximum width, W max , a minimum width, W min , and the ratio of W max :W min  is at least 1.1:1.0. 
     
     
       7. The packing element of  claim 6  wherein said ratio of W max :W min  is at least 1.2:1.0. 
     
     
       8. The packing element of  claim 6  further comprising a height H, which is the minimum distance between said first planar surface and said second planar surface, wherein the ratio of W max :H is between 2:1 and 10:1. 
     
     
       9. The packing element of  claim 8  wherein the ratio of W max :H is between 3:1 and 7:1. 
     
     
       10. The packing element of  claim 1  wherein the shape of said second planar surface is non-circular. 
     
     
       11. The packing element of  claim 1  having a total geometric surface area comprising vertically exposed surface area and vertically non-exposed surface area wherein at least 50 percent of the total geometric surface area is vertically exposed surface area. 
     
     
       12. The packing element of  claim 11  wherein the ratio of exposed surface area to non-exposed surface area is at least 2:1. 
     
     
       13. The packing element of  claim 11  wherein the ratio of exposed surface area to non-exposed surface area is at least 4:1. 
     
     
       14. A process for manufacturing mass transfer packing elements comprising the steps of:
 (a) providing a mixture of sinterable, ceramic materials; 
 (b) extruding the mixture along a central axis to form an extrudate, said extrudate comprising a peripheral wall which surrounds a passageway therethrough, a first internal wall and a second internal wall disposed within said passageway, said first internal wall defines a first geometric plane, said second internal wall defines a second geometric plane; 
 (c) dividing said extrudate into a plurality of uniformly shaped packing elements by cutting said extrudate along cutting planes which intersect said central axis at an acute angle, thereby forming a first end which defines a first planar surface and a second end which defines a second planar surface; wherein said first and second geometric planes intersect said first and second planar surfaces at an acute angle and said geometric planes defined by said first and second internal walls are mutually parallel; and 
 (d) sintering said uniformly shaped packing elements. 
 
     
     
       15. The process of  claim 14  wherein at least one of said cutting planes and said central axis form an angle less than 80°. 
     
     
       16. The process of  claim 14  wherein at least one of said cutting planes and said central axis form an angle less than 70°. 
     
     
       17. The process of  claim 14  wherein at least one of said cutting planes and said central axis form an angle less than 60° and greater than 30°. 
     
     
       18. The process of  claim 14  wherein at least two of said cutting planes are mutually parallel. 
     
     
       19. The process of  claim 14  wherein all of said cutting planes are mutually parallel. 
     
     
       20. The process of  claim 14  wherein said cutting comprises a cutting member selected from the group consisting of a wire and a liquid. 
     
     
       21. The process of  claim 20  wherein said cutting comprises two cutting members simultaneously cutting said extrudate. 
     
     
       22. The process of  claim 20  wherein said cutting comprises moving said wire through said extrudate. 
     
     
       23. A process for manufacturing mass transfer packing elements comprising the steps of:
 (a) providing a mixture of sinterable, ceramic materials; 
 (b) extruding the mixture along a central axis to form an extrudate, said extrudate comprising a peripheral wall which surrounds a passageway therethrough; 
 (c) dividing said extrudate into a plurality of uniformly shaped packing elements by cutting said extrudate along cutting planes which intersect said central axis at an acute angle wherein said cutting comprises selecting a cutting member selected from the group consisting of a wire and a liquid and rapidly forcing said liquid through said extrudate. 
 
     
     
       24. A chemical processing apparatus comprising a vessel, said vessel comprises a first fluid entry point, a second fluid entry point, a fluid exit point and a bed of randomly oriented packing elements disposed between said first and second entry points, wherein at least a majority of said packing elements each comprise a continuous peripheral wall comprising a first end and a second end, wherein said peripheral wall surrounds a passageway through said element and said first end defines a first planar surface; and disposed within said passageway, a first internal wall defines a first geometric plane and a second internal wall defines a second geometric plane, said geometric planes are mutually parallel and intersects said first planar surface at an acute angle. 
     
     
       25. The chemical processing apparatus of  claim 24  wherein said bed of packing elements consists essentially of said packing elements. 
     
     
       26. The chemical processing apparatus of  claim 24  wherein said bed of packing elements consists of said packing elements.